Generation of high octane hydrogen gas from acetic acid

ABSTRACT

A device and method for generation of high octane hydrogen gas from acetic acid includes providing an electrolysis unit having a cathode, an anode, neutral elements, gaskets, and an electrolyte including acetic acid; applying pulse-width-modulated power to the cathode and anode to produce hydrogen and oxygen gas from the electrolyte; transporting the gas and some of the electrolyte from the electrolysis unit to a reservoir; transporting the electrolyte in the reservoir back to the electrolysis unit, thereby reusing the electrolyte; refilling the reservoir with distilled water when the level of electrolyte in the reservoir is low; utilizing a condensate trap to dump water that condenses out of the gas in the reservoir; and transporting the gas in the condensate trap for use. The hydrogen and oxygen gas may be provided to the air intake of an engine.

RELATED APPLICATIONS

This application claims the benefit of the filing date of U.S. PatentApplication No. 61/224,194, filed Jul. 9, 2009, which is incorporatedherein by reference in its entirety.

BACKGROUND OF THE INVENTION

The present invention generally relates to generation of hydrogen gasand more specifically to generation of high octane hydrogen gas fromacetic acid.

Existing internal combustion engines for automobiles may burn only 20%of the carbon in the gasoline or diesel fuel. Carbon is sent to acatalytic converter, which is wasteful, and produces emissions thatinclude noxious gasses and green house gasses, such as carbon monoxide(CO), carbon dioxide (CO2), and nitrous oxide (NO).

The use of on-board electrolysis in producing small amounts of hydrogenand oxygen gasses into the air intake of an internal combustion enginemay increase mileage and reduce emissions from the automobile.

It would be therefore be desirable to have a device that may be usefulto an individual, business or corporation who desires or needs areduction in fuel consumption and has a desire to reduce emissions, suchas, for example trucking companies, police departments, school systems,individuals who commute to and from work, and others who wish to reduceemissions.

SUMMARY OF THE INVENTION

In one aspect of the present invention, a device for producing a gasincludes an electrolyte; an electrolysis unit that retains theelectrolyte; a cathode inside the electrolysis unit; a positive leadelectrically connected to the cathode; an anode inside the electrolysisunit; a negative lead electrically connected to the anode; a neutralelement inside the electrolysis unit, between the cathode and anode; apulse width modulator that provides pulse-width-modulated power to theleads so that the cathode and anode react with the electrolyte toproduce a gas; a first conduit that transports gas and electrolyte inthe electrolysis unit to a reservoir; a second conduit that transportsthe electrolyte in the reservoir to the electrolysis unit; and a thirdconduit that transports the gas in the reservoir out of the device,thereby producing the gas.

In another aspect of the present invention, a device for producing a gasincludes an electrolysis unit that retains an electrolyte, theelectrolyte including acetic acid; a cathode inside the electrolysisunit, having a metal plate and a cathode tab electrically connected to apositive lead; an anode inside the electrolysis unit, having a metalplate and an anode tab electrically connected to a negative lead; aneutral plate between the cathode and anode, the anode, cathode, andneutral plate oriented generally parallel to each other inside theelectrolysis unit; a plurality of gaskets between the plates; a pulsewidth modulator that provides pulse-width-modulated power to the leadsso that the cathode and anode react with the electrolyte to produce agas that includes hydrogen and oxygen; a first conduit that transportsgas and electrolyte in the electrolysis unit to a reservoir; a secondconduit that transports the electrolyte in the reservoir to theelectrolysis unit; and a third conduit that transports the gas in thereservoir out of the device, thereby producing the gas.

In yet another aspect of the present invention, a method of producing agas includes providing an electrolysis unit having a cathode, an anode,a neutral element between the cathode and anode, gaskets therebetween,and an electrolyte including acetic acid; applying pulse-width-modulatedpower to the cathode and anode to produce gas from the electrolyte, thegas substantially containing hydrogen and oxygen; transporting the gasand some of the electrolyte from the electrolysis unit to a reservoir;transporting the electrolyte in the reservoir back to the electrolysisunit, thereby reusing the electrolyte; refilling the reservoir withdistilled water when the level of electrolyte in the reservoir is low;utilizing a condensate trap to dump water that condenses out of the gasin the reservoir; and transporting the gas in the condensate trap foruse, thereby producing the gas.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a schematic depiction of an embodiment of the presentinvention;

FIG. 2 depicts a condensate trap according to the embodiment of FIG. 1;

FIG. 3A depicts a top view of an electrolysis unit according to theembodiment of FIG. 1;

FIG. 3B depicts a side view of the electrolysis unit of FIG. 3A;

FIG. 4A depicts a positive plate according to the embodiment of FIG. 1;

FIG. 4B depicts a negative plate according to the embodiment of FIG. 4A;and

FIG. 4C depicts a neutral plate according to the embodiment of FIG. 4A.

DETAILED DESCRIPTION

The preferred embodiment and other embodiments, which can be used inindustry and include the best mode now known of carrying out theinvention, are hereby described in detail with reference to thedrawings. Further embodiments, features and advantages will becomeapparent from the ensuing description, or may be learned without undueexperimentation. The figures are not necessarily drawn to scale, exceptwhere otherwise indicated. The following description of embodiments,even if phrased in terms of “the invention” or what the embodiment “is,”is not to be taken in a limiting sense, but describes the manner andprocess of making and using the invention. The coverage of this patentwill be described in the claims. The order in which steps are listed inthe claims does not necessarily indicate that the steps must beperformed in that order.

An embodiment of the present invention generally generates high-octanehydrogen gas from acetic acid. Embodiments may provide, for example, 115octane hydrogen gas. Embodiments may be self-contained units that, whenconnected to an automobile or other vehicle's battery and engine airintake, provide hydrogen gas to improve mileage and reduce emissions.

An embodiment of a device may burn fuel that is otherwise normallyexhausted. The device may generate high-octane hydrogen gas that is usedby the motor. An embodiment may use electrolysis of acetic acid andother chemicals to generate, for example, 115 octane hydrogen gas at 5pounds per square inch. Elements of an embodiment of the device mayinclude a polycarbonate resin thermoplastic, such as, for example,Lexan®, which houses stainless steel plates and silicone gaskets. Steelbolts may be used for assembly. Electrical terminals may be made ofbrass. Tubing for acetic acid circulation may include polyurethane, suchas, for example, Superthane®. A reservoir may contain acetic acid usedfor the electrolysis. A circulation pump for the acid may be 12 volt,and may be driven by the automobile battery. Hydrogen gas or vapor maybe generated by electrolysis. Gaskets may provide insulation. The aceticacid may be circulated and reused. Embodiments may produce hydrogen gas,which is collected and output.

Embodiments may introduce hydrogen gas into the air intake of aninternal combustion engine, such as an engine for an automobile thatuses gasoline, diesel fuel, natural gas, or propane. The hydrogen mayhelp provide a complete and rapid burn of all carbon in the fuel for theengine, which may improve mileage and reduce emissions of emittingnoxious gasses and green house gasses including carbon monoxide, carbondioxide, and nitrous oxide. The hydrogen may be produced throughelectrolysis or hydrolysis, by a system operated from the automobilebattery. The hydrogen may be produced on demand, only when theautomobile is on, and thereby avoid the need for a dedicated gas holdingtank.

As depicted in FIG. 1, an embodiment of a system 10 may utilize abattery 12, such as a 12-volt automobile battery or a dry cell,electrically connected to a relay 14. Battery 12 also provides power toa system controller/pulse width modulator (PWM) 16. Embodiments of PWM16 may incorporate other functions of the system, such as relay 14. PWM16 may be a pre programmed microcontroller or other computer, and mayprovide pulse-width modulated power to an electrolysis unit 18, which isa fuel cell or hydrogen-cell that utilizes an electrolyte such as aceticacid for hydrolysis. Gaseous hydrogen, oxygen, and aerosol electrolytefrom the electrolysis unit 18 may be delivered to a reservoir 20, whichis a tank for electrolyte to be re-used, and gasses to be externallyoutput. Condensed liquid electrolyte in the reservoir 20 may be returnedto the electrolysis unit 18 as needed using a circulation pump 22 thatruns continuously. The hydrogen and oxygen gasses in reservoir 20 may beprovided to a water condensate trap 24 which may be delivered as anexternal fuel output 40 to the air intake of an internal combustionengine. Excess water 38 formed by condensed hydrogen and oxygen in thewater condensate trap 24 may be dumped as needed. To replace this dumpedexcess water 38, distilled water may be provided to the reservoir 20from a reserve water tank 26 as needed. A dashboard unit 28 may displaysystem status from PWM 16 and receive control inputs from a user. Pump22 may continuously pump electrolyte from the reserve 20 to theelectrolysis unit 18 through an electrolysis recharge line 32. This mayhelp blow the bubbles of hydrogen and oxygen off of the plates in theelectrolysis unit 18, as well as help provide pressure to urge themixture of hydrogen, oxygen, and electrolyte to pass through theelectrolysis recharge line 32.

The level of acetic acid or other electrolyte in the reserve 20 may bedetected by an electrolyte float switch 30, and if the level is low, areserve water tank 26 located adjacent or near the reservoir 20 may pumpdistilled water with a water pump 42 through a water valve 44 into awater pipe 46 and into the reservoir 20. The addition of distilled waterfrom water valve 44 may be controlled by PWM 16 based upon signalsreceived from electrolyte float switch 30. The gasses produced by theelectrolysis unit may be collected and provided to the reservoir 20through an electrolysis gas line 34. Hydrogen and oxygen in thereservoir 20 may be provided to the water condensate trap 24 through ahydrogen and oxygen fuel line 36. Power and control lines 48 may providestatus information to the controller/pulse width modulator (PWM) 16 fromcomponents of the system, which may include the reserve water tank'swater pump 42 and water valve 44, the reservoir 20, the circulation pump22, and the water condensate trap 24. This status information may beinterchanged using a data line 50 with a dashboard unit 28, so that auser may provide control inputs to adjust the proportions and balancesof the system. An embodiment of a PWM 16 may receive direct current (DC)power 52 such as 12-volt DC power from an automobile battery 14, andprovide pulse-width modulated power 54 to the electrolysis unit 18.Embodiments of electrolysis unit 18 may be determined by the size of theinternal combustion engine, which may be, for example, 4-cylinder,6-cylinder, 8-cylinder, or diesel.

An embodiment of a pulse width modulator 16 may be used to control theamperage and voltage sent to the electrolysis unit 18. In someembodiments, the PWM 16 rate may range from 300 to 3,000 pulses persecond. The amperage may control both the supply of hydrogen gasproduced and the amount of heat built up in the unit. An embodiment of aPWM 16 may function to help retard heat. The greater the amperage, themore hydrogen gas will be produced.

An embodiment of a dashboard unit 28 may be a free-standing element thathas a computer or other control mechanism which sets the desiredamperage of the PWM 16. Users may use the dashboard unit 28 to makechanges. Dashboard unit 28 may include a display screen, such as aliquid crystal display (LCD), that tells the user if there is a failureat any point in the system, such as, for example, a low electrolytelevel in the reservoir 20. The dashboard unit 28 may also indicate theelectrolyte temperature, and might shut the system down for a period oftime or decrease the amperage.

Embodiments may provide automatic refill, in that an extra reserve watertank 26 distilled water may be kept adjacent to reservoir 20. When thelevel of acetic acid becomes low in reservoir 20, electrolyte floatswitch 30 in the reservoir 20 tank electrically trips, which triggerswater pump 42 and water valve 44 to transfer fresh distilled water fromreserve water tank 26 to reservoir 20. When replenished, water pump 42shuts off and water valve 44 closes.

In an embodiment, acetic acid at 5% strength by volume may be stored inthe electrolysis unit and may be used as an electrolyte because it ischemically stable, safe for humans, safe for the environment, and safefor internal combustion engines. The resulting hydrolysis product mayhelp burn carbon build up which may have accumulated over years and mayimprove engine performance. Metal plates may be used to accomplishhydrolysis, and may be titanium coated with iridium tin, or ceramiccovered stainless steel plates, or possibly plain stainless steelplates. However, the latter choice may produce hexavalent chromium whichmay be considered toxic in some areas, such as California. To performhydrolysis, the electrolyte, such as 5% acetic acid with distilledwater, may enter an embodiment of a dry electrolysis unit and may beintroduced to the plates. Some plates may have leads that are attachedto the automobile's positive terminal, which may act as cathodes, andother plates may have leads that are attached to the automobile'snegative terminal, which may act as anodes, and yet other plates may beneutral. Hydrogen atoms, having negative electrons, will arise at thecathodes, and oxygen atoms, having positive protons, will arise at theanodes.

As depicted in the embodiment of FIG. 2, a water condensate trap 24 mayreceive hydrogen and oxygen gas from a fuel line 36, dump excess water38, and deliver an external fuel output 40 to an outside entity such asthe air intake of an engine. Power and control lines 48 may power andcontrol a condenser float switch 60 that measures the level of condensedgas 62. An embodiment of condensate trap 24 may include a closedcontainer that accepts the gaseous products of electrolysis produced inelectrolysis unit 18. This gaseous product may be a type of aerosol, andwhen it arrives in the container via hydrogen and oxygen fuel line 36,the outside temperature and the heat of the gas produces watercondensate 62 consisting substantially of water, in addition to fuel gas64. The pressure of the fuel gas 64, which consists substantially ofhydrogen and oxygen, may force moisture to separate and drop to thebottom of water condensate trap 24 as a condensate which in turn formsinto a liquid water condensate 62. As this liquid rises, at a certainlevel it trips a condenser float switch 60 or electronic valve in thefloor, and the condensate liquid 62 exits through a water dump tube 66in the floor of the trap 24. In the meantime, the hydrogen and oxygengasses rise and move through external fuel output 40 into the air intakeof the internal combustion engine. An electronic condenser valve 70, inresponse to a signal from condenser float switch 60, may open to dumpthe water condensate 62 out of the system through a condenser outputtube 72.

Embodiments may include an oxygen sensor 68 in line with the externalfuel output 40, as may be mandated by the Environmental ProtectionAgency. Embodiments of the system may include a special chip or othersensor component to assist in oxygen detection. When high oxygen levelsare detected, a control system may regulate the production of oxygen.

As depicted in the embodiment of FIGS. 3A and 3B, an electrolysis unit18 may include a number of plates including positive plates 80, negativeplates 82, and neutral plates 84. As depicted in FIG. 3A, the plates maybe organized as +NN−NN+, with positive plates 80 electrically connectedto the positive lead 88 and negative plates 82 electrically connected tothe negative lead 90, and with two neutral plates between each positiveand negative plate. Other embodiments may include, for example,−NN+NN−NN+NN−, −NNN+NNN−NNN+NN−, or −NN+NN−. Additional configurationsmay be made. A positive lead 88 may electrically connect the positiveplates 80, which have a tab in a first orientation such as tab up, and anegative lead 90 may electrically connect the negative plates 82, whichmay be similar to the positive plates except that they are in a secondorientation such as tab down. One or more electrolysis input sockets 94in the front of the electrolysis unit 18 may connect to the electrolysisrecharge line 32 near the bottom of the electrolysis unit 18 to receiveelectrolyte from the reservoir. The acetic acid may be forced into theelectrolysis unit 18 under pressure by the circulation pump, which willhelp blow the bubbles of hydrogen and oxygen gas off of the plates,helping enhance hydrolysis. One or more gas output sockets 96 in theback of the electrolysis unit may connect to the electrolysis gas line34 to send the products of hydrolysis to the reservoir. The outputsockets 96 may be located approximately 1.5 inches from the top of theelectrolysis unit, so as to extract the gasses produced by hydrolysis,and also to uptake the electrolyte when the unit is full of electrolyte(thereby helping make room for gasses in the electrolysis unit as gassesare produced).

As depicted in FIGS. 4A, 4B, and 4C, plates 80, 82, and 84 have gaskets92 for insulation between the plates. Positive plates 80 have a tab in afirst orientation such as tab up, and negative plates 82 may be similarto the positive plates except that they are in a second orientation suchas tab down. Neutral plates 84 may help provide space betweenalternating positive and negative plates in the electrolysis unit.

Embodiments of the present invention may be packaged in a singlehousing, and all elements kept within, except wires and tubes and thedashboard unit. The package may be steel for automobiles or plastic fortrucks. In automobiles, the package may be located in the trunk. Intrucks, or diesels, the package may be bolted to the frame.

1. A device for producing a gas, comprising: an electrolyte; anelectrolysis unit that retains the electrolyte; a cathode inside theelectrolysis unit; a positive lead electrically connected to thecathode; an anode inside the electrolysis unit; a negative leadelectrically connected to the anode; a neutral element inside theelectrolysis unit, between the cathode and anode; a pulse widthmodulator that provides pulse-width-modulated power to the leads so thatthe cathode and anode react with the electrolyte to produce a gas; afirst conduit that transports gas and electrolyte in the electrolysisunit to a reservoir; a second conduit that transports the electrolyte inthe reservoir to the electrolysis unit; and a third conduit thattransports the gas in the reservoir out of the device, thereby producingthe gas.
 2. The device of claim 1, wherein the electrolyte is aceticacid, the cathode produces hydrogen, the anode produces oxygen, and thegas includes the hydrogen and the oxygen.
 3. The device of claim 1,wherein the anode is a metal plate, the cathode is a metal plate, theneutral element is a plate, and the anode, cathode, and neutral elementare oriented generally parallel to each other inside the electrolysisunit.
 4. The device of claim 3, further comprising: gaskets between theplates.
 5. The device of claim 1, wherein the anode includes iridium tinand the cathode includes iridium tin.
 6. The device of claim 1, whereinthe cathode has a cathode tab, the cathode lead is connected to thecathode tab, the anode has an anode tab, and the negative lead isconnected to the anode tab.
 7. The device of claim 1, furthercomprising: a pump to urge the electrolyte in the reservoir through thesecond conduit to the electrolysis unit so that the electrolyte helpsblow bubbles of gas produced by the anode and the cathode off of theanode and the cathode.
 8. The device of claim 1, further comprising: acondensate trap that receives gas from the reservoir, dumps condensatethat condenses from the gas out of the trap, and provides the gas to thethird conduit to be transported out of the device.
 9. The device ofclaim 1, further comprising: a water reserve that contains water; and asensor that determines the level of electrolyte in the reservoir;wherein, when the sensor determines that the level of electrolyte in thereservoir is low, water in the reserve is provided to the reservoir soas to raise the level of electrolyte.
 10. The device of claim 1, whereinthe third conduit is adapted to produce the gas to the air intake of anengine, and the pulse width modulator is adapted to obtain directcurrent power from a battery.
 11. The device of claim 1, furthercomprising: a display screen that provides device status to a user; anda control input that provides an input from the user to the pulse widthmodulator.
 12. A device for producing a gas, comprising: an electrolysisunit that retains an electrolyte, the electrolyte including acetic acid;a cathode inside the electrolysis unit, having a metal plate and acathode tab electrically connected to a positive lead; an anode insidethe electrolysis unit, having a metal plate and an anode tabelectrically connected to a negative lead; a neutral plate between thecathode and anode, the anode, cathode, and neutral plate orientedgenerally parallel to each other inside the electrolysis unit; aplurality of gaskets between the plates; a pulse width modulator thatprovides pulse-width-modulated power to the leads so that the cathodeand anode react with the electrolyte to produce a gas that includeshydrogen and oxygen; a first conduit that transports gas and electrolytein the electrolysis unit to a reservoir; a second conduit thattransports the electrolyte in the reservoir to the electrolysis unit;and a third conduit that transports the gas in the reservoir out of thedevice, thereby producing the gas.
 13. The device of claim 12, furthercomprising: a pump to urge the electrolyte in the reservoir through thesecond conduit to the electrolysis unit so that the electrolyte helpsblow hydrogen bubbles off of the cathode plate and oxygen bubbles off ofthe anode plate.
 14. The device of claim 12, further comprising: acondensate trap that receives hydrogen gas and oxygen gas from thereservoir, dumps water that condenses from the gasses out of the trap,and provides the gasses to the third conduit to be transported out ofthe device.
 15. The device of claim 12, further comprising: a waterreserve that provides distilled water to the reservoir when electrolytein the reservoir is low.
 16. The device of claim 12, further comprising:a dashboard unit, electrically connected to the pulse width modulator,having a status display screen and a control input.
 17. The device ofclaim 12, further comprising: a dashboard unit, electrically connectedto the pulse width modulator, having a status display screen and acontrol input.
 18. A method of producing a gas, comprising: providing anelectrolysis unit having a cathode, an anode, a neutral element betweenthe cathode and anode, gaskets therebetween, and an electrolyteincluding acetic acid; applying pulse-width-modulated power to thecathode and anode to produce gas from the electrolyte, the gassubstantially containing hydrogen and oxygen; transporting the gas andsome of the electrolyte from the electrolysis unit to a reservoir;transporting the electrolyte in the reservoir back to the electrolysisunit, thereby reusing the electrolyte; refilling the reservoir withdistilled water when the level of electrolyte in the reservoir is low;utilizing a condensate trap to dump water that condenses out of the gasin the reservoir; and transporting the gas in the condensate trap foruse, thereby producing the gas.
 19. The method of claim 18, furthercomprising: pumping the electrolyte in the reservoir into theelectrolysis unit to help enhance hydrolysis.
 20. The method of claim18, further comprising: transporting the gas that is produced to an airintake of an engine for a vehicle having a battery; and powering theelectrolysis unit utilizing power from the battery so that the gas isproduced when the vehicle is on.